Automotive sleeve: Cpk 1.89 in one operation
A stainless sensor sleeve made in three operations moved to one Swiss-type cycle, and PPAP was approved at first submission.
Sample case study: the customer and figures are fictional.
Challenge
An automotive supplier's sensor sleeve was turned, milled and deburred in three separate operations. Capability on the Ø 6 h6 diameter stayed at Cpk 1.12, which held up series approval.
Solution
We moved the part to a Swiss-type lathe with a sub-spindle: front and back work, the cross hole and deburring run in one cycle. The critical diameter is measured every 50 parts and charted for SPC.
Result
Cycle time fell from 92 to 38 seconds and operations from three to one. Cpk on the critical diameter rose to 1.89, and the PPAP level 3 file was approved at first submission.
Before and after
| Measure | Before | After |
|---|---|---|
| Operations | 3 | 1 |
| Cycle time | 92 s | 38 s |
| Cpk on critical diameter | 1.12 | 1.89 |
| Unit cost index | 100 | 64 |
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